I moved house earlier this year and one of the jobs that needed doing was to strip and repaint the internal doors and frames. The living room door had been damaged by, what looks like, someone forcing it open and had been crudely repaired with a nailed on bit of hardboard.
This is the damaged area after the door has been stripped and the previous repair removed.
I then stood and looked at it for half an hour trying to figure how I could cleanly remove all the broken wood and leave a flat surface using a router. The door isn't very flat and there are no consistant reference surfaces to mount some kind of jig to so, hand tools it had to be. Not my forté!
That went better than expected and I cut up some filler pieces and, once trimmed to fit, glued them in.
Next came the final piece, I had to router out a shallow recess to allow the lock to fit and glued it into place.
I left the upper surface a few mm proud and planed it down to be level with the rest of the door. It was quite easy but there was some horrible tear out which I dealt with with this somewhat irreverently titled liquid wood (fa means wood). I have to build up the moulding with this as well as I don't have a tool to cut the shape.
Almost done and then I'll get the paint on it, drill a hole for the handle spindle and put the mechanism and new handle on.